High Efficiency Power Controller for Solid State Lighting

ABSTRACT

A high efficiency power controller comprising of a driver circuit to convert to direct current (DC) voltage from alternating current (AC) voltage is used for drive solid state lighting (SSL) including light emitting diode (LED) and organic light emitting diode (OLED). The driver circuit is comprises of an AC-DC limited current unit, sensor processor, signal generator, feedback controller and SSL lamp module, which converts the AC supply voltage to a DC voltage by using a negative feedback current and voltage limiting circuit for powering SSL. The invented driver circuit operates at high efficiency with low power consumption. The current and voltage feedback circuit mode from current, voltage, light intensity and thermal temperature for SSL possesses reliable DC power driver without any flash during lighting.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to power controller including an alternating-current (AC) to direct-current (DC) converter and a feedback controller and a sensor processor used for Solid State Lighting (SSL), and more particularly to a high efficiency power controller for a SSL lamp module which may include a Light Emitting Diode (LED) array or an Organic Light Emitting Diode (OLED) panel. This invention can find particular application where the LED array and OLED panel is utilized in a lamp for general illumination. In comparison with a filament lamp or fluorescent lamp, SSL lamps demonstrate a significant number of advantages, such as low power consumption, long useful lifetime, small volume, light weight, and being environment friendly. The efficiency of the high brightness LED is higher than that of the filament lamp or fluorescent lamp. Therefore, the use of the LED lamp for general illumination application will be spread significantly. A high efficiency and reliable power controller to convert AC to DC for the SSL driver is desired for general illumination.

2. Description of the Related Art

As well known, a LED operates with a few volts of direct-current (DC) power supply voltage, and emits a small amount of illumination. For practical lighting application, an array of many LEDs which are connected either in series or parallel, or a combination of series and parallel, is needed to achieve a desired illumination flux. Thus, a power supply controller should be provided to convert the commercial alternating-current (AC) power to DC voltage, a transformer based AC-DC converter and/or a pulse width modulation (PWM) controller is conventionally used.

A LED for a lighting application requires high power supply to improve the illumination flux. The LED operates at high operating current, i.e. 0.35 A for 1 W LED, 1 A for 3 W LED, 1.5 A for 5 W LED, 3 A for 10 W LED, and the additional thermal dissipation associated with increased power of LED, high current and power can cause significant thermal problems. Therefore, enhancing the efficiency of the LED driver to reduce power consumption would be a considerable advantage, particularly for general illumination applications.

Conventionally, a transformer and a PWM method are used for AC-DC converter. The transformer in the converter normally consumes some power; the high frequency pulse associated with PWM can generate a flash for SSL illumination, which is detrimental for human eyes during lighting; and also can reduce the lifetime of SSL. Besides, the power consumption can increase greatly when it operates at high current condition, and the reliability will rapidly decrease. In addition, the power efficiency of SSL lighting is lower if the transformer and PWM power controller are used at high current. The transformer and PWM type of AC-DC converter may have a typical efficiency of 70-80%, while the charge pump type of AC-DC converter usually has efficiencies more than 80% when the capacitor in the circuit is considered.

For general lighting application, AC power such as 220V and 110V is used, but the supplied AC voltage is not stable and can vary about ±20% in most cases, affecting the lighting intensity of the SSL during the operation of the SSL. The working current for SSL changes exponentially with the changing applied voltage. If the voltage increases, the current for the SSL is greatly increased, resulting in a reduced the SSL lifetime or even destroying the device. In addition, at high current, load variable, temperature, light intensity, transistors, diodes, resistors in the driver circuit are not stable during operation, and as a consequence, the performance of all electronic devices and LEDs/OLEDs degrade greatly.

SUMMARY OF THE INVENTION

In view of the foregoing and other problems, disadvantages, and drawbacks of the conventional methods and structures, an object of the present invention is to provide a high efficiency and reliable power controller for SSL lamps, which overcomes the above problems.

Another object is to provide a high efficiency SSL driver circuit which utilizes a capacitor to regulate the SSL driving current, providing high efficiency and low power consumption. Meanwhile, the feedback circuit by sensing current, voltage, temperature, or light intensity can tune the power supply for the operation of the SSL and can maintain a reliable and stable power during the operation of the SSL.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages will be better understood from the following detailed description of a preferred embodiment of the invention with reference to the drawing, in which:

FIG. 1 shows a schematic diagram of the power controller, in accordance with the present invention.

1, AC-DC limited current unit; 2, Feedback controller; 3, SSL lamp module; 4, Sensor processor (multi-signal collector comparator); 5, Standard signal generator.

12, DC current; 14, I&V samples; 21, Control signal; 23, DC power (I&V); 34, bright/thermal signals; 42, control signal; 54, Standard signal.

01, AC power connecting portion; 02, bridge circuit; 03, rectifying diodes; 04, capacitor; 05, resistor; 06, sensing resistor; 07, field effect transistor; 08, current controller; 09, comparator circuit.

DETAILED DESCRIPTION

The present invention provides a high efficient and reliable power controller to convert AC to DC to supply the SSL for general illumination application. In particular, the present invention provides an improved driving circuit with more than 90% power efficiency for SSL devices.

-   -   As shown in FIG. 1, a power controller in this invention for SSL         application includes the following parts: 1, AC-DC limited         current unit; 2, Feedback controller; 3, SSL lamp module; 4,         Sensor processor (multi-signal collector comparator); 5,         Standard signal generator; 12, DC current; 14, current and         voltage samples; 21, Control signal; 23, DC power based on         current and voltage; 34, brightness and/or thermal signals; 42,         control signal; 54, standard signal.

The AC-DC limited current unit (1) having an AC power connecting portion 01 for being connected to a power source, and a bridge circuit 02 connected to AC power source, which converts the AC supply voltage to a DC voltage at a limited current (12); The AC power connecting portion 01 is connected to the commercial AC110±10V and AC230±20V power supply. The bridge circuit 02 includes rectifying diodes 03 to converter AC to DC, and a capacitor 04 and a resistor 05 having a first side connected to the bridge circuit 02.

The SSL lamp module 3 may include LEDs, or OLED; and the SSL lamp module (3) comprises LED arrays, or OLED panel.

The DC current (23) from the feedback controller (2) is sent to the SSL lamp module (3); The SSL lamp module 3 collects the signals (34) from the SSL lamp module (3) and sends the signal 34 to the sensor processor (4). The sensor processor 4 sends a control signal (42) to the feedback controller (2), the feedback controller 2 sends a feedback control signal (21) to the AC-DC limited current unit (1), and DC current/power (23) to the SSL lamp module (3) is controlled in accordance with the feedback control signal 21. The standard signal generator (5) generates a standard signal (54) of the current and voltage as a threshold current and voltage for the sensor processor 4 to use, which varies according to the DC power 23 supplied to SSL lamp module (3).

The sample signal (14) which corresponds to the variable voltage and current 12 in the AC-DC limited current unit (1) can be sent to the sensor processor (4), and the sensor processor 4 sends a control signal (42) through the feedback controller (2) to a feedback control signal (21) to the AC-DC limited current unit (1), and (23) to the SSL lamp module (3). For general lighting application, the commercial AC power such as 220V and 110V is used, the voltage may possible be variable about ±20%, and the variable signal can be feedback to maintain a stable DC output to the SSL lamp.

The sensor processor (4) is a multi-signal collector and comparator used for processing the working current and voltage signals, or that converted by lighting intensity and thermal temperature signals (34) from SSL lamp module (3); The multi-signal collector comparator comprises a sensing resistor 06 adapted to be connected to the SSL lamp module (3), the sensing resistor 06 may be as thermistor, and/or photosensor. If the working temperature of the LED is above a predetermined level such as 100° C., the lifetime of the LED is greatly reduced. The thermistor can provide a signal to the sensor processor 4 and feedback controller 2 to limit the current supply to the LED, thus greatly increases the lifetime of the LED lamp module. The photosensor can detect the varying brightness of the LED lamp. If the lighting intensity has changed a lot, the photosensor can provide a signal to the sensor processor and feedback loop circuit to limit the current supply to the LED, thus greatly increasing the uniformity and repeatability of LED lamp module during lighting.

The AC-DC limited current unit (1) comprising capacitors, inductors and resistors connected to the diode based bridge circuit 02; rectifying the received alternating current for generating a DC power. This unit can convert AC power such as 220V and 110V to DC voltage from 3 to 300V, and current from 0.01 to 10 A, and the power efficiency is not less than 90%.

The feedback controller (2) comprises a field effect transistor 07 having a drain connected to a cathode of the SSL lamp module (3), a source connected to the lower voltage terminal of the power supply and a gate connected to receive the electrical signal. A feedback controller 2 connected to the SSL, including a current controller 08 and comparator circuit 09 for comparing a reference and feedback for sensing and regulating load voltage and current 23.

The feedback controller 2 outputs DC output (23) for SSL lamp module (3), and a positive terminal of the bridge circuit 02 is connected to an anode of the SSL lamp module 3, and the field effect transistor 07 having a drain connected to a cathode of the SSL lamp module 3.

The power controller including an AC-DC limited current unit 1, feedback controller 2, sensor processor 4 and signal generator 5 may be fabricated as one integrated circuit chip. The power efficiency is more than 90% for SSL applications.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed. 

1. A power controller for solid state lighting (SSL), comprising: an AC-DC limited current unit for supplying power to the solid state lighting; a feedback controller coupled to the AC-DC limited current unit; a sensor processor coupled to the feedback controller; a signal generator coupled to the signal processor; a SSL lamp module coupled to the feedback controller;
 2. The power controller of claim 1, wherein the SSL lamp module includes at least one of emitting diode (LED), and/or organic light emitting diode (OLED); and wherein the SSL lamp module comprising at least one of LED arrays, and/or OLED panel.
 3. The power controller of claim 1, wherein the AC-DC limited current unit includes an AC power connecting portion for being connected to a power source, and a bridge circuit connected to AC power source, which converts the AC supply voltage to a DC voltage at a limited current.
 4. The power controller of claim 1, wherein the feedback controller collects the signals from the SSL lamp module and the sensor processor, sending the control signals to the AC-DC limited current unit;
 5. The power controller of claim 1, wherein the sensor processor includes a multi-signal collector comparator to process the working current and voltage, and to process the lighting intensity and thermal temperature from SSL lamp module; and to send feedback signals to the AC-DC limited current unit.
 6. The power controller of claim 1, wherein the signal generator transmits the current and voltage to the sensor processor according to the SSL lamp module working power condition.
 7. The power controller of claim 1, wherein the AC-DC limited current unit comprising capacitors, inductors and resistors connected to the diode based bridge circuit; rectifying and filtering the received AC for generating a DC power supply to the SSL lamp module.
 8. The power controller of claim 1, wherein the AC-DC limited current unit includes a first side for connection to an AC input and a second side for connection to the feedback controller to connect the DC power supply to the SSL lamp module for lighting application.
 9. The power controller of claim 1, wherein the variations in the current and voltage can be compensated by the feedback controller through the sensor processor to make a stable DC power output to the SSL lamp module.
 10. The power controller of claim 1, wherein AC input connection comprises commercial AC in the range of approximately 110±10V to 230±20V power supply; and wherein the DC voltage is in the approximate range of 3-300V.
 11. The power controller of claim 3, wherein the bridge circuit comprises a rectify diode to converter AC to DC, a capacitor, and at least one of a inductor or a resistor having a first side connected to the bridge circuit.
 12. The power controller of claim 4, wherein the feedback controller for current limit comprises a field effect transistor having a drain connected to a cathode of the SSL lamp module, a source connected to the lower voltage terminal of the power supply and a gate connected to receive an electrical signal.
 13. The power controller of claim 1, wherein the feedback controller includes a bridge circuit having a positive terminal connected to an anode of the SSL lamp module, and a field effect transistor having a drain connected to a cathode of the SSL lamp module.
 14. The power controller of claim 5, wherein the multi-signal collector comparator comprises a sensing resistor adapted to be connected to the SSL lamp module, and wherein the sensing resistor includes at least one of a thermistor, and/or photosensor and wherein the feedback loop circuit connected to the SSL module includes a current controller and comparator circuit for comparing a reference and feedback for sensing and regulating load voltage and current.
 15. The power controller of claim 1, wherein the power controller can be tuned change the brightness of the SSL lamp module.
 16. The power controller of claim 1, wherein the power controller including an AC-DC limited current unit, feedback controller, sensor processor and signal generator are fabricated as one integrated circuit chip.
 17. The power controller of claim 1, wherein the power factor is above 0.8, showing capacitive type load.
 18. The power controller of claim 1, wherein the power efficiency is more than 90% for SSL applications. 